Spec. No. ELRS/SPEC/ELC/0019,REV ï – î3 4 -...

Page No. 1 of 31 Issued on ……….2017 Spec. No. ELRS/SPEC/ELC/0019,’REV’ – ‘3’ 4

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lR;eso t;rs

GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS

INDIAN RAILWAYS TECHNICAL SPECIFICATION

FOR

THIN WALLED FLEXIBLE ELASTOMERIC CABLES

WITH COPPER CONDUCTORS

FOR

WORKING VOLTAGES

(i) UPTO 750 VOLTS

AND

(ii) ABOVE 750 VOLTS UPTO 1.8/3.0KV

(FOR TAP CHANGER ELECTRIC LOCOMOTIVES, AC/DCEMU, BG AC

EMU& MEMU/COACHING STOCK)

Specification No. ELRS/SPEC/ELC/0019, (REV-3 4)

ELECTRICAL DIRECTORATE

RESEARCH DESIGNS & STANDARDS ORGANISATION

MANAK NAGAR, LUCKNOW – 226011

APPROVED BY SIGNATURE

EDSE(CO-ORD)



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Status of Revision

S. N. Date of

Revision

Clause No. Revision Reasons for Revision

1. 06.07.2010 Amendments made in

relevant pages and the same are renumbered

1 i) Incorporation of provisions

contained in the guidelines & approval of Railway Board

circulated vide their letters dated 20.03.09 & 27.04.10 ii)

Inclusion of all Amendments of Rev 0 of spec in the main

text of Rev 1.

2. 21.02.2011 Amendments made in

relevant pages and the same are renumbered

2 Incorporation of provision

contained in the approval of Railway Board vide their

letter dated 06.12.2010 regarding use of single layer

insulation/sheath for cable upto 750V with EVA material

for conventional electric locomotives and correction of

dimension in Data Sheets 1A& 2A.

3 22.02.2017 1.5, 2.1 ,3.2.3 ,7.1.2,7.1.3,7.2.1(c,d),

7.2.4, 7.2.5,7.2.8, 7.2.13,7.2.15,7.2.21,7

.2.22,7.2.24,7.3.2,7.4.1(c,d),11.4

3 Incorporation of provision contained in Railway Board

2016/ML/Misc dated 16-5-16 for using improved

polymers for manufacture of cables capable of

withstanding high temperature i.e. at least 150

deg C instead of 120 deg C and in turn other changes.

4 …….2017 3.1.1, 7.2.1.(a)(i)(ii)

Datasheet1A,2A,&2B.

4 In specification Typical value

of strands and nominal value of dia are mentioned. However

these are not required as per referred IS 8130-2013. there

are some Typographical mistake. Which are to be

corrected.



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TECHNICAL SPECIFICATION FOR ELECTRON BEAM IRRADIATED/CHEMICALLY CURED

CROSS LINKED THIN WALLED FLEXIBLE ELASTOMERIC CABLES WITHCOPPER

CONDUCTORS FOR TAP CHANGER ELECTRIC LOCOMOTIVES (WITH DC TM) AND

COACHING/AC/DC EMU, BG AC EMU &MEMU STOCK.

(FOR WORKING VOLTAGE UPTO 750 VOLTS AND ABOVE 750 VOLTS UPTO 1.8/3.0KV)

1.0 SCOPE:

1.1 Specification no SLRS/SPEC/ELC/004 of June 1999 for thin walled cables for Electric

Locomotive was issued specifying both Chemical Curing & Electron Beam Radiation Curing

Process but only one table of dimensions of Cable/ Insulation thickness and Tolerance was

indicated there. With the development of electron beam irradiated cables indigenously and to

get full advantage of precise control of dimension, separate tables were given for chemical &

Electron beam curing process and Specification No. ELRS/SPEC/ELC/0019 of May 2002

was issued. It is also observed that different Production Units are following different

Specifications for the same type of cables. In the present version, details of Multi core cables

and all four Amendments specified in earlier version of specification have been included and

the specification has been made uniform all Railway/Production units to make it complete

for adoption of thin walled cables on existing Tap Changer Electric Locomotive with DC drives

and Coaching/AC/DC EMU, BG AC EMU & MEMU Stock. Based on the experience gained by

IR with coaches imported and manufactured now for Rajdhani / Shatabdi Express trains, in

consonance with the trend being adopted worldwide for control voltage cable and also to

ensure uniformity in specifications adopted by different PUs/ Railways, this specification

provides for use of single/double layer of cable insulation/sheath for working voltages upto

750 volts for Tap Changer Electric Locomotives/ EMU/Coaching Stock and use of double

layer of insulation/ sheath for working voltage above 750 volts for Electric Locomotives and

EMU/Coaching Stock.

1.2. This specification covers the design / performance requirements of Electron Beam

Irradiated/ chemically cured thin walledflexible cables with copper conductor for use in

power, auxiliary as well as control circuits of conventional Tap Changer Electric Locomotives,

AC/DC EMU, and BG AC EMU & MEMU/Coaching stock. The cables shall be of limited fire

hazard type i.e. minimum flame spread, low smoke emission and limited toxic fume

emission.

1.3 The specification is applicable to meet the requirements of cables for working voltage up to

750 volts (with single / double layer insulation) for tap changer Electric Locomotives, AC/DC

EMU, BG AG EMU&MEMU/Coaching stock, and above 750 volts up to 1.8 KV /3KV grade

cables (with one layer of insulation and one layer of sheath) for Tap Changer Electric

Locomotive AC/DC EMU, BG AC EMU and MEMU / Coaching Stock.



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1.4 The Cables shall be suitable for continuous operation at conductor temperature of 1200C.

1.5 All the provisions contained in RDSO’s ISO procedures laid down in Document No. QO-D-

7.1-11 dated 19-7-16 (titled “vendor –Changes in approved status”) and subsequent

versions/amendments thereof shall be binding and applicable on successful vendor/vendors

in the contracts floated by Rail ways to maintain quality of products supplied to Railway.

2.0 TEST METHOD AND REQUIREMENTS:

2.1 General:

The tests are classified as product development Tests. Type Tests, Routine test and

Acceptance Tests. All thermal tests shall be carried out in oven capable of maintaining

uniform heating inside.

2.1.1 Product development tests:

There tests shall be carried out on the insulation and sheath materials to establish:

(a) Safe working temperature(1200C)

(b) Life (Arrhenius Plot – 20,000 hrs as per IEC 60216 at1200C)

(c) Infrared spectrograph (Polymer identification)

2.1.2 Type Tests:

These tests shall be carried out to prove conformity with the requirement of specification

and design feature of the cable. Complete type tests on two sizes, one lowest & one highest

size (for control cable upto 750 volts grade for single core and multicore separately as per

CL.3.2.1)and on two size, one lowest and one highest size (for cables above 750V grade and

upto 1.8KV /3.0 KV as per Clause 3.2.2) of cable shall be carried out. In case of any change

in the material, manufacturing process or design of the cable by the manufacturer or as

desired by the client in the interim period, completed type tests shall be repeated.

2.1.3 Routine tests:

These tests shall be carried out on all finished cable length to ensure consistency of the

produce. However, the purchaser may carry out these tests on sample taken at random as

per the relevant specification to verify the result observed by the manufacture.



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2.1.4 Acceptance tests:

These Tests are to be carried out on the samples taken from a lot for the purpose of

acceptance of the lot.

3.0 MATERIAL:

3.1 CONDUCTORS:

3.1.1 The conductor shall be made up with circular tinned, annealed copper wires complying

with the requirement of IS:8130 – 1984 2013 with flexibility of Class – 5. Nominal cross –

sectional area, maximum single wires dia of conductor, and maximum resistance of

conductor at 20 deg.C shall be as per data sheet 1A(with chemical curing process- single

core cables ) and 2A&2B,(With e – beam curing process – single core and 19 core cables).

Bunching of wires up to 10.0 sq. mm. may be concentric /rope construction. For

conductor sizes above 10.0 sq.mm. only rope stranded bunching of wires shall be adopted.

3.1.2A Polyester separator Tape of red or any other distinguishing colour shall be applied over the

conductor. However, for manufacture of cables using Electron Beam Curing process,

provision of separator tape on the conductor is not mandatory.

3.2 INSULATION AND SHEATHING:

3.2.1 For cable upto 750 volts grade (for tap changer electric locomotive and AC/DC EMU, BG AC EMU& MEMU / Coaching stock):

Insulation shall be of one layer with material being EEA/EMA/EVA. This shall serve the

purpose of insulation as well as sheath for this application. Testing voltage, requirement

and parameters of this type of cable have been specified in the testing Clauses separately,

wherever they are different. For construction, dimension and conductor resistance, refer

Table 1 of Datasheets 1A &2A.

OR

Insulation and sheath arrangement shall be of two layers with material as per CL.3.2.2 off

this specification. Testing voltage requirement of this type of cable in this cable case shall

also be same be same as for cables of CL.3.2.2.For construction, dimension and

resistance, refer Table 2 of Data sheets 1A, & 2A and Table 1 of Data sheet 2B.

The component used for insulation/sheath shall be halogen free and suitable for

continuous operating temperature of conductor at 1200C. The manufacture shall

establish the Infra Red Spectrograph of material and furnish the same to RDSO. In case

of any change in the material, the manufacturer shall obtain RDSO’s approval before



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adoption. The manufacturer will establish test facilities for Infra Red Spectrography at

their works itself.

3.2.2 For cable above 750 volts and upto 1.8/3.0 KV (for tap changer electric locomotives and AC/DC EMU, BG AC &MEMU/Coaching stock):

Material to be used for insulation shall be EPDM and that for sheathing shall be

EEA/EMA/EVA. The compounds used for insulation and sheath shall be halogen free and

suitable for continuous operating temperature of conductor at 1200C. The manufacture

shall establish the Infra Red Spectrograph of material and furnish the same to RDSO. In

case of any change in the material, the manufacturer shall obtain RDSO’s approval before

adoption. The manufacturers will establish test facilities for Infra RedSpectrograph at their

works itself. For construction, dimension and conductor resistance, refer Table 2 of Data

sheets 1A, & 2A and Table 1 of Data sheet 2B.

3.2.3 The curing of the insulation/ sheath shall be by:

Chemical cross linking process presently adopted for Elastomeric Cables

OR

Electron – beam cross linking process.

Electron – beam cross linking process, the requirements shall be governed by RDSO’sSTR NO.–RDSO/2017/EL/STR/0087, Rev’0’ or latest.

In case the curing is by chemical cross linking process, the requirements shall also be Governed by RDSO’s STR NO.–RDSO/2007/EL/STR/0020, Rev’0’ or latest.

4.0 CONSTRUCTION:

The conductor formation, minimum thickness of insulation sheath and tolerance in overall diameter of the cable with chemical curing process shall be according to Data sheet 1A enclosed. Similar data for cables with electron –beam –cross linking process will be as given

in Data sheets 2A& 2B enclosed.

5.0 COLOUR Unless specifically indicated the color of the outer sheath shall be black.

6.0 IDENTIFICATION , PACKING AND MARKING

6.1 IDENTIFICATION

The following details shall be printed on the sheath of the cable at every 1000 mm. (a) Manufacture Name/Trade Mark. (b) Rated voltage



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(c) Year of manufacture (d) Indication of insulation material and its operating temperature. (e) Nominal cross –sectional area of the conductor.

6.2 PACKING AND MARKING

6.2.1 All cables shall have their ends sealed with non-hygroscopic sealing materials. 6.2.2 The cables shall be either wound on reels or drum or supplied in coils packed and

labeled. 6.2.3 The label of the stenciling on the drum shall contain the following information:

(a) Reference specification number, (b) Manufacture’s name , brand name or trade mark, (c) Type of cable and voltage grade, (d) Number of cores, (e) Nominal cross –sectional area of the conductor, (f) Length of the cable on the drum/reel/coil, (g) Number of lengths of the reel, drum or coil (if more than one ), (h) Direction of rotation of drum (by means of arrow ), (i) Approx. gross weight & (j) Year of manufacture

7.0 TESTS, TEST METHODS AND REQUIREMENTS

Tests shall be made by the manufacturers at their expense to the compliance with all

requirements of this specification. The tests shall be made in presence of

authorizedrepresentative of RDSO/production unit /Zonal Railway. Separate test for 750

V grade single layer/double layer cable indicated in CL. 3.2.1 used for Tap Changer

Electric Locomotives, AC/DC EMU, BG AC EMU&MEMU/Coaching stock and for above

750 and upto1.8/3.0 KV grades cables indicated in CL. 3.2.2 used for Tap Changer

Electric Locomotives AC/DC EMU,BG AC EMU&MEMU/Coaching stock applications

respectively have been indicated, wherever required.



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7.1 PRODUCT DEVELOPMENT TESTS(for all grades of cables)

CLAUSE NO.

NAME OF THE TESTS 1

REQUIREMENTS

2

TEST METHORD

3

7.1.1 Test for identification of rubber polymers used for insulation and sheathing.

-

ASTM – D -3677 -83 (or latest version)

7.1.2 Mechanical properties of the insulation. tensile strength as received elongation as received variation after heat ageing 10 days at 180+ 30C

>10N/mm sq. > 150% +30%

IS:10810- Part -7 IS: 10810 -Part – 11

7.1.3 Mechanical properties of the Sheath. - tensile strength as received - elongation as received - variation after heat ageing 10 days at 180+ 30C

>10N/mm sq. > 150% +30%

IS: 10910 Part – 7 IS: 10810 Part – 11 Where dumb – bell specimen cannot be prepared , tubes of the combined sheath and insulation shall be used

7.1.4 Thermal Endurance Test & duration of usability Elongation at break absolute

IEC60 216Arrhenius plot >50% after 20000Hrs at 120+20C

7.1.5 Weatherability of sheath material

Elongation at break>80% (exposure 14 days)

ASTM G53-1984

7.1.6 Resistance to Cleaner for 24 hours at room temp. (ordinary soap solution)

No cracks or other deterioration in Sheath and Insulation layer. No breakdown when tested according to CI.7.2.1(c)

Test arrangement according to CI.7.2.15.1 of this specification. The specimen shall be immersed in specified medium for the described test duration. The ends of the specimen shall rise above the test medium at least 50 mm.



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7.2 TYPE TESTS ON COMPLETE CABLE (for both voltage grades)

CLAUSE

NO

NAME OF THE TESTS

1

REQUIREMENTS

2

TEST METHODS

3

7.2.1 Test on conductor/ cable

(a) (i) Composition of conductor.

technical data sheet 1A, 2A &2B

As per clause – 11.7 of this specification.

(ii) Persulphate test.

CI.6.1.1 of IS: 8130 –

1984 2013

Part – 4 of IS: 10810-

1984 or Latest.

(iii) Annealing test.

CI.6.1.2 of IS: 8130 – 1984. 2013

Part – 1 of IS: 10810-1984 or Latest.

(iv) Resistance test. Technical data sheet 1A,2A&2B

Part -5 of IS : 10810-1984.

(b) Test for thickness of insulation & sheath

Technical data sheet 1A,2A&2B

Part -6 of IS : 10810-1984.

(c) High voltage test

(water immersion test)

6kV,50 Hz 5 Min. (For 750V grade single layer cable of CL.3.2.1) after water immersion for 24 hour at room temperature, No break down.

Part 45 of IS: 10810 - 1984 cable length: 3 to 5 meters

8KV , 50 Hz , 15 Min.(For

above 750 V & upto 1.8/3 KV grade cable of CI.3.2.2) after water immersion for 24 hours at room temperature No break down

part 45 of IS: 10810-1984 cable length: 3 to 5 meters



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(d) Insulation Resistance test i) For 750 V grade single

layer cable of CI.3.2.1 At room temp At 90+ 3 deg.C

(Insulation resistance constant) K>2000Mega ohms Km K>30Mega ohms Km

Part 43 of IS : 10810-1984

ii)For cable above 750 V and upto 1.8/ 3 KV grade cable of CI.3.2.2 At room temp. At 90+ 3 deg.C

K >12000Mega ohms Km K >200Mega ohms Km

Part 43 of IS : 10810-1984

(e) DC stability test Water immersion for 10 days No breakdown at 750 V DC (for 750 volts grade single layer cable of CI.3.2.1) and 1800 V DC (for above 750 V &upto 1.8/3 KV grade cable of CI.3.2.2).

clause -11.4 0f this specification

7.2.2 Dielectric strength > 8 KV (for 750 v grade single layer cable of CI.3.2.1).

Clause – 11.6 of this specification

>15 KV (for above 750 V &upto 1.8/3.0 KV Grade cable of CI.3.2.2). No BD occurs at less than this voltage

7.2.3 Tracking resistance

Cross section <2.5 mm sq. 4-16 mm sq. 25-95 mm sq. 120-150 mm sq. Tracking Voltage Break Down voltage

current consumption

after 10 sec. at 2 KV (for 750 V grade single layer cable of CI.3.2.1) ≤1.0 m A ≤1.5 m A ≤2.0 m A ≤2.5 m A > 07 KV > 10 KV

Clause – 11.5 of this

specification



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<2.5 mm sq. 4-16 mm sq. 25-95 mm sq. 120-300 mm sq. Tracking Voltage Break Down voltage

(For above 750 V &upto1.8/3.0 KV grade cable of CI.3.2.2) ≤ 1.0 m A ≤ 1.5 m A ≤ 2.0 m A ≤ 2.5 m A > 20 KV > 25 KV


7.2.4 Mechanical properties of the

insulation. - tensile strength as received - elongation at break as received - variation after heat ageing for 10 days at 180+ 3 deg.C

>10N/mm sq. > 150% +30%

IS: 10810- part -7 IS: 10810 -part – 11

7.2.5 Mechanical properties of the Sheath. - tensile strength as received - elongation at break as received - variation after heat ageing for 10 days at 180+ 3 deg.C

>10N/mm sq. > 150% +30%

IS: 10910 part – 7 IS: 10810 part – 1 Where dumb – bell specimen cannot be prepared , tubes of the combined sheath and insulation shall be used

7.2.6 Tear Resistance of the Insulation & Sheath

Tearing force >2.5 N/mm

IS: 10810 part 17

7.2.7 Stripability for section 1.5 to 6mm sq.

The admissible stripping Force shall be between the min. and max. Values. The conductor shall not be damaged and shall be free orresidues.

Appendix ‘A’ of this specification

7.2.8 Hot set test IS: 10810 part – 30 Insulation and sheath

Max. elongation - under load < 100 % -after cooling <15% Test temp. 200±3 deg.C Test load 20N/cm.sq

IS: 10810 Part – 30



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7.2.9 Shrinking Shrinkage <1.5 mm Length of specimens300mm, Test temp. 180 +3 deg.C Exposure time 6 hours.

IS: 10810 Part- 12

7.2.10 Heat shock No cracking in sheath or Insulation layer. Test temp. 180 + 3 deg.C Mandrel dia according to CI.7.2.15.1 of this Specification. Exposure

time 1 hour.

IS: 10810 Part 14

7.2.11 Dynamic cut through resistance

The mean value P for 4 test , each with 90degree rotation of the specimen and 100 mm longitudinal displacement, shall not be lower than The value give in the following table.

Clause 11.3 of this specification

Cut through force P(N)

Cross section (mm sq.) 23+ 2deg.C 70+ 2deg.C

2.5 > 100N >30N

35 >300N > 80 N

7.2.12 Notch sensitivity (Applicable for double layer Cable of CI 3.2.1.and 3.2.2)

No breakdown when tested according to CI .7.2.1 (c)

Appendix ‘C’ of this specification

7.2.13 Pliability Recoil angle≤30 deg. No breakdown when tested according to CI.7.2.1 (c)

Appendix ‘D’ of this specification

7.2.14 7.2.14.1 7.2.14.2

Abrasion resistance of - sheath (Applicable for double layer Cable of CI 3.2.1.and 3.2.2) -Marking (indelibility )

The scrape abrasion resistance shall not be less than 1200double stroke. No continuous strip shall be visible On the marking under 150 double stroke

Appendix ‘ B ‘ of this specification Appendix ‘ B ‘ of this specification



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7.2.15

Windability (deformation) of the finished cable.

7.2.15.1

-As received

No cracking in sheath or insulation layer.No breakdown when tested according to CI .7.2.1(c)

Clause – 11.2 of this specification. Mandrel cable Dia dia 3 x D for ≤10mm 5 x D for > 10 ≤20mm 8 x D for > 20mm

7.2.15.2

After ageing for 10 days at180 ± 3 deg.C

No cracking in sheath or insulation layer. No break down when tested according to CI 7.2.1(c)

Mandrel dia according to CI.7.2.15.1. Thetestspecimen in straight from shall be aged during 10 days at 180±3 deg.C before

winding.

7.2.15.3 At -15±2deg.C No cracking in sheath or insulation layer. No break down when tested according to CI 7.2.1(c)

Mandrel dia according to Cl.7.2.15.1. of this specification .The test specimen shall beaged in the straight form during 10days at 180±3

deg.C before deposited for 4 hours in cold box.

7.2.16 Impact at -15±2deg.C No cracking in sheath or insulation layer.No break down when tested according to CI.7.2.1(c)

Test specimen as received and after ageing in air oven during 10 days at 180±3 deg.C

7.2.17 Slippage test

The relevant displacement of the conductor with insulation shall not be more than 10mm for cables with 25mm dia and 15mm for cables over 25mm dia respectively

Clause-11.8 of this specification. A sample length 350±5mm is

taken and bent to a radius for 150mm.

7.2.18 Ozone Resistance test 275±25 ppm 96 hours at

room temperature. No cracks in sheath or insulation layer. No breakdown when tested according to 7.2.1(c)

IS:10810-Part-13



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7.2.19 Resistance to fluids No cracks or other deterioration in sheath and insulation layer. No breakdown when tested according to Cl 7.2.1 (c)

IS: 10810 Part-31 Mandrel dia according to Cl. 7.2.15.1 of this specification. The specimen shall immersed in the specified in medium for the described test duration. The ends of the specimen shall rise

above the test medium at least 50mm.

7.2.19.1 Mineral oil 100±2 deg.C

24 hours

-do- -do-

7.2.19.2 Diesel oil 70±2 deg.C

168 hour

-do- -do-

7.2.19.3 Cleaner at Room temp. for 24 hours (ordinary Soap solution)

-do- -do-

7.2.20 Flame Retardant (single cable)

Charred length ≤200mm Cease of burning ≤30 sec.

IS:10810 Part-61

7.2.21 Flame Propagation (Bunched Cable)

The charred or affected portion should not have reached a height exceeding 2.5 m above the bottom edge of the burner.

IEC 60332-3(Cat. C)

7.2.22 Corrosively of Combustion Gaseson sheath only

Ph- Index≥4.3 Electrolytic conductivity ≤100 micro Siemen/cm

IEC60754-2

7.2.23 Toxicity of Combustion Gasses on sheath only

Toxicity index≤5 Gases as per UITP part 2E7&Test method as per NES713

7.2.24 Smoke Density on sheath only

SDR-20%max. ASMT-D-2843 or latest

7.2.25 Test for identification of rubber polymers (Insulation & Sheath)

Material shall be according to Cl . 3.2.1 & 3.2.2

ASTM –D-3677-83 or Latest



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7.3 ROUTINE TESTS:

CLAUSE NO

NAME OF THE TESTS 1

REQUIREMENTS 2

TESTS METHODS 3

7.3.1 Conductor Resistance Technical Data sheet 1A, 2A and 2B

IS:10810 – part – 5

7.3.2 High Voltage Test (Water immersion test)

6kV,50 Hz. 15 Min.(For 750V grade single layer cable of CI.3.2.1) after immersion in water for 24 hours at room temp. No breakdown.

IS:10810- part- 45 cable length: 3 to 5 meters

8 kV, 50 Hz 15 min (for above 750 V and upto1.8/3 KV grade cable of CI.3.2.2after immersion in water for 24 hours at room temp. No breakdown.

IS:10810- part- 45 cable length: 3 to 5 meters

7.3.3 Spark Test 6KV ( for 750V grade single layer Cable as per CI.3.2.1) 15 KV (for above 750 V and upto 1.8/3.0 KV No breakdown

SI:10810- part- 44

7.4ACCEPTANCE TESTS :

CLAUSE NO

NAME OF THE TESTS 1

REQUIREMENTS 2

TESTS METHODS 3

7.4.1

(a)

Test on conductor/ cable (i) Composition of conductor

(ii) Persulphate test.

(iii) Annealing test.

(iv) Resistance test.

Technical data sheet 1A, 2A &2B

CI.6.1.1 of IS: 8130 – 1984. 2013 CI.6.1.2 of IS: 8130 – 1984. 2013 Technical data sheet 1A,2A&2B

As per clause – 11.7 of this specification.

Part – 4 of IS: 10810 – 1984. Part – 1 of IS: 10810-1984. Part -5 of IS: 10810 -1984.

(b) Test for thickness of insulation & sheath

Technical data sheet 1A,2A&2B

Part -6 of IS : 10810-1984.



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(c) High voltage test (water immersion test)

6kV,50 Hz 5 Min. (For 750V grade single layer cable of CL.3.2.1) after water immersion for 24 hour at room temperature, No break down.

IS:10810- Part- 45 cable length: 3 to 5 meters

8kV , 50 Hz , 15Min.(For above 750 V &upto 1.8/3 KV grade cable of

CI.3.2.2) after water immersion for 24 hours at room temperature No break down

IS:10810- Part- 45 cable length: 3 to 5 meters

(d) Insulation resistance test (i)For 750 V grade single layer cable of CI.3.2.1 At room temp At 90+ 3 deg.C (ii)For cable above 750 V and upto 1.8/ 3 KV grade cable of CI.3.2.2 At room temp. At 90+ 3 deg.C

Insulation resistance constant

K>2000 Mega ohms Km K>30Mega ohms Km K >12000 Mega ohms Km K >200Mega ohms Km

Part 43 of IS : 10810-1984

(e) DC stability test Water immersion for 10 days No breakdown at 750 V DC (for 750 volts grade single layer cable of CI.3.2.1) and

1800 V DC (for above 750 V &upto 1.8/3 KV grade cable of CI.3.2.2).

Clause -11.4 0f this specification

(f) Tracking resistance Cross section <2.5 mm sq. 4-16 mm sq. 25-95 mm sq. 120-150 mm sq. Tracking Voltage Break Down voltage

Current consumption after 10 sec. at 2 KV (for 750 V grade single layer cable of CI.3.2.1) ≤1.0 m A ≤1.5 m A ≤2.0 m A ≤2.5 m A >07KV >10KV




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<2.5 mm sq. 4-10 mm sq. 25-95 mm sq. 120-300 mm sq. Tracking Voltage Break Down voltage

(For above 750 V&upto 8/3 KV grade cable of CI.3.2.2) ≤1.0 m A ≤1.5 m A ≤2.0 m A ≤2.5 m A >20KV >25KV


7.4.2 Strippability for section 1.5 to 6mm sq.

The admissible strippingforce shall be between the min. and max. Values. The conductor shall not be damage and shall be free or residues.

Appendix ‘A’ of this specification

7.4.3 Windability (deformation) of the finished cable

7.4.3.1 -As received

No cracking in sheath or insulation layer. No breakdown when tested according to CI.7.2.1(c)

Clause – 11.2 of this specification. Mandrel cable diadia 3 x D for ≤10mm 5 x D for > 10 ≤20mm 8 x D for > 20mm

7.4.3.2 After ageing for 10 days at180 ± 3 deg.C

No cracking in sheath or insulation layer. No break down when tested according to CI 7.2.1(c)

Mandrel dia according to CI.7.2.15.1. The test specimen in straight from shall be aged during 10 days at 180 ± 3 deg.Cbefore winding.

7.4.3.3 At -15±2deg.C No cracking in sheath or insulation layer .No break down when tested according to CI 7.2.1(c)

Mandrel dia according to Cl.7.2.15.1. of this specification.The test specimen shall be aged in the straight form during 10 days at 180 ±3 deg.C before

deposited for 4 hours in cold box.



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7.4.4 Test for identification of rubber polymers (Insulation & Sheath)

Material shall be according to Cl . 3.2.1 & 3.2.2

ASTM –D-3677-83 OR Latest

7.4.5 slippage test The relevant displacement of the conductor with insulation shall not be more than 10mm for cable with 25mm dia and 15mm for cable over

25mm dia respectively

Clause -11.8 of this specification a sample let length 350±5mm is

taken and bent to a radius for 150mm.

8.0 CORE IDENTIFICATION :

8.1 The core of 19 core cable shall be identified by numbers printed on the cores. The numerals

printed on cores shall appear at intervals of not greater than 150 mm.

8.2 For 19 core cables, used in tap changer electric locomotive the core identification shall be

done by numbers. The core shall be numbered sequentially, starting with number 1 for

inner layer. The number shall be printed in Hindi – Arabic numerals on the outer surface of

the cores. All the numbers shall be of the same colour, which shall contrast with the colour

of insulation. The numeral shall be legible.

8.2.1For 19 core 2.5 sq. mm. control cables and 4.0 sq. mm. jumper cables in AC /DC EMU, BG

AC EMU & MEMU/Coaching Stock the core identification shall be done by sequential

numbers starting with number 1 at the outer layer and end at the central core. The

increasing numbers in all layers shall be in the same direction .The number shall be printed

in Hindi-Arabic numerals on the outer surface of the cores. All the numbers shall be of the

same colour, which shall contrast with the colour of the insulation. The numerals shall be

legible.

8.3 Arrangement of marking – The numbers shall be repeated at regular intervals along the core,

consecutive numbers being inverted in relation to each other.

When the number is a single numeral, a dash shall be placed below it. If the number

consists of two numerals, these shall be disposed one below the other and a dash placed

below the lower numeral.

9.0 LAYING UP OF CORES:

9.1 In case of 19 core cables, the core shall be laid together with a suitable right hand lay in

accordance with clause 11 of IS : 1554 ( part 1 ) – 1988. The outer most layers shall have

right hand lay and successive layers shall be laid with opposite lay. Fillers in interstices may



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be provided to ensure reasonable circularity of laid up cables. The filler material shall be

suitable for the operating temp. of 120 deg.C.

The value of the lay for 19 core cable shall be max. 12 times the pitch circle diameter.

10.0 SAMPLING :

The sampling plan for acceptance tests shall be as follows:

10.1 LOT

In a consignment, the cable of the same size manufactured under essentially similar

conditions of production shall be grouped together to constitute a lot.

10.2 SCALE OF SAMPLING

10.2.1 Samples shall be taken be and tested from each lot for ascertaining the conformity of the

lot to the requirement of the specification.

10.2.2 The number of samples to be selected shall depend on col. 1 and 2 as indicated below.

These samples shall be taken at random.

No of drums/coils/Reels in the lot (N) (1)

No of drums coils/ reels to be taken as sample (n) (2)

Permissible No. of defectives. (a) (3)

Up to 25 3 0

26 to 50 5 0

51 to 100 8 0

101 to 300 13 1

301 to above 20 1

10.2.2.1 In order to ensure the randomness of selection. Procedure given in SI: 4905 – 1968 may

be followed.

10.3 NUMBER OF TESTS AND CRITERION FOR CONFORMITY:

Suitable length of the test samples shall be taken from each of the drums selected. These

test samples shall be subjected to each of the acceptance tests. A test sample is called

defective if it fails in any one of the acceptance tests. If the number of defective is less than

or equal to the corresponding permissible number given in col.3 under 10.2.2, the lot shall

be declared as conforming to the requirements of acceptance tests; otherwise not.



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11.0 SELECTED TEST METHODS:

11.1 Some of the test methods as specified under various clauses of this specification are given

below from clauses 11.2 to 11.8.

11.2 WINDABILITY (DEFORMATION) TESTS:

The test-pieces shall be wound round a mandrel with a dia of :-

- 3Dfor cable dia ≤ 10 mm

- 5D for cable dia> 10 ≤ 20mm

- 8D for cable dia>20 mm, being the external dia. of the cable, and in such a way as to

form 10 continuous turns in a right-hand direction. This procedure shall be followed 3

times.

The test-pieces shall be unwound carefully straightened and rewound 3 times on the same

mandrel, in such a way as to form 10 continuous turns in a left- hand direction side so

that the external surface of the cable situated on the outside during first operation is now

on the inside. No cracks visible to the naked occur.

The cable shall withstand the high voltage test after the cable has been subjected to the

above bending test.

11.3 DYNAMIC CUT THROUGH RESISTANCE:

This test shall be carried out on sample of cable, using a tensile tester operating in a

compression mode. The tester shall be equipped with a chart recorder which shall be

suitable for recording the force necessary to force a flat tungsten carbide edge (90 deg.

Included angle with a 0.127mm flat edge )through the covering of a sample cable. The

tester shall also be equipped with a chamber which will allow the test to be performed at

elevated temperature and a low voltage detection circuit designed to stop the tester when

the cutting edge cuts through the covering and comes in contact with the conductor.

The sample of cable of suitable length shall be placed on a hard flat surface so that the

cutting edge is perpendicular to the axis of the cable. The cutting edge shallbe moved

through the covering at a constant rate of 5 mm/min.

Four test shall be performed on each sample and moved forward 25 mm minimum. and

rotated clockwise 90deg. between each test. The average of the four tests shall be the cut

through resistance which shall be greater than the minimum value as mentioned in clause

7.2.11. The cut through test shall be performance with the cable samples at 20 deg. C and

70+ 2deg. C.



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11.4 DC STABILITY TEST :

This test is carried out on cable with a single covering using direct current to ensure that

the mechanical characteristics of the single covering. Which permit the commission of the

protection sheath, retains adequate insulating properties.

The test shall be carried out on samples 5 meters long. The samples shall be continuously

immersed .expect for its end which shall project about 250 mm. for 240 hours in a water

bath in which sodium chloride has been dissolved to a proportion of 10 gms per litre. The

temperature of water shall be 65deg.C ± 5 deg. C .the conductor of the sample shall be

connected to the negative pole of the DC supply of 750 V DC for 750 V grade single layer

cable of CI.3.2.1 and 1800 volts for double layer cable of CI.3.2.1 and CI. 3.2.2. The positive

of the DC supply shall be connected to a copper electrode immersed in the water (Without

galvanic connection in the container).

There shall be no breakdown of the insulation during the 240 hours test. There shall

be no damage to the outer surface of insulation: discoloration shall be ignored.

11.5 TRACKING RESISTANCE :

The annular electrode shall consist of at least 3 continuous turns of copper wire of about

1.8 mm dia. Care must be taken when applying the electrode to ensure that the cable is not

damaged. The sample with two annular electrodes 50.mm apart shall be bent into a single

loop and placed in water for four hours at a temp. from 15 to 20 deg. C. The ends of the

cable shall project at least 50mm above the surface of the water. After this immersion, the

samples shall be removed and dried with non- fluffy filter paper. Immediately afterwards

the leakage current shall be measured by a milli-ammeter when a voltage of 2000 V 50 Hz

is applied for 10 sec. between the electrodes. The voltage shall then be raised at the rated of

100V per second until tracking occurs followed by a flashover. The value of leakage

current, tracking voltage and breakdown voltage shall be as under:-

Maximum leakage current

Cross sectional area of copper Max. Leakage current after 10 seconds at 2 KV.

(a) (for 750 V grade single layer cable of CI.3.2.1)

(i) Tracking voltage – surface tracking shall not occur below 07 KV

(ii) Breakdown voltage – flashover shall not occur below 10 KV

(b) (for above 750 V&upto 1.8/ 3 KV grade cable of CI.3.2.2)

(i) Tracking voltage – surface tracking shall not occur below 20 KV

(ii) Breakdown voltage – flashover shall not occur below 25 KV



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11.6 TEST FOR DIELECTRIC STRENGTH:

A sample of cable of 1 meter length shall be immersed in water for 24 hours and thereafter

an alternating voltage of 50 Hz shall be applied between the conductor and water,

commending from 6000 V and increasing in steps of 750V every 30 seconds until puncture

occurs. The voltage at which puncture occurs shall not be less than 15 KV.

11.7 COMPOSION OF CONDUCTOR:

All wires must be of the same nominal dia. The dia of wires must not differ from the

nominal dia beyond the tolerance ± 0.01 mm.

The dia. Of wire shall be measured by means of a ratchet micrometer or a dia micrometer,

between smooth faces circular in shape and with a dia of at least 5mm. the average of the

readings of a two measurements taken at right angle to each other shall be accepted as the

value of the dia.

11.8 SLIPPAGE TEST:

A sample of length approximately 350mm is taken and bent to a radius of 150 mm. the

relative displacement of the conductor with insulation shall not be more than 10mm for

cable upto 25 mm dia. And 15 mm for cables over 25 mm dia.



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DATA SHEET – 1A

CHAMICAL CURING PROCESS – SINGLE CORE CABLE

CONSTRUCTION, DIMENSION AND CONDUCTOR RESISTANCE TEMPERATURE

RANGE:-40 TO + 120 DEG.C

MIN. BENDING RADIUS FOR OD < 10MM = 3 X D & OD > 10MM = 5 X D

Table 1

1. For control cable upto 750 volts grade with single layer insulation/ sheath for Tap changer of Electric

Locomotive AC/DC EMU. BG AC EMU & MEMU/Coaching Stock as per CI.3.2.1 of specification

SL. No.

Nominal cross

sectional

area of

core (mm2)

No of wires (typical value)

x single wire

dia (max) of

conductor

(n x mm dia)

Conductor dia.

Nominal

(mm)

Minimum wall

thickness of

insulation/

sheath

(total)(mm)

Overall cable Dia (D)

(mm)

Max. resistance

of

conductor

at 20 deg. C

(ohm/Km)

1 25.0 198 x 0.41 6.8 0.96 8.90 + 0.50 0.795

2 35.0 266 x 0.41 7.8 1.10 10.20 + 0.50 0.565

3 50 .0 385 x 0.41 9.5 1.20 11.90+ 0.50 0.395

4 70.0 348 x 0.51 11.5 1.30 14.30 + 0.50 0.277

5 95.0 468 x 0.51 12.9 1.40 15.90 + 0.50 0.210

6 120.0 589 x 0.51 14.8 1.50 17.90+ 0.50 0.164

7 150.0 741 x 0.51 16.3 1.60 20.30 + 0.50 0.132

1. Rope stranded conductor construction shall be adopted from sizes 10. Sq. mm and above

2. As per clause no. 3.2 of IS 8130:2013 Nominal cross sectional area of conductor is the value that identifies a

particular size of conductor but is not subject to direct measurement.

3. Each particular size of conductor is required to meet a maximum resistance value as per IS 8130-2013.

Table 2

2. For cable above 750 Volts and upto 1.8/3.0 KV as per CI.3.2.2 of specification for Tap

changer of Electric Locomotive & AC/ DC EMU, BG AC EMU & MEMU/Coaching stock

SL.

No.

Nominal

cross

sectional area of

core

(mm2)

No of wires

(typical value)

x single wire dia (max) of

conductor

(n x mm dia)

Conduc

tor dia.

Nominal

(mm)

Minimum wall thickness Overall cable

Dia (D)

(mm)

Max.

resistance

of conductor

at 20 deg. C

(ohm/Km)

Insula

tion

(mm)

Shea

th

(mm)

Total

(mm)

1 25.0 198 x 0.41 6.8 0.60 0.80 1.40 10.6+ 0.5 0.795

2 35.0 266 x 0.41 7.8 0.65 0.85 1.50 12.1 + 0.5 0.565

3 50 .0 385 x 0.41 9.5 0.70 0.90 1.60 14.0+ 0.5 0.395

4 70.0 348 x 0.51 11.5 0.75 0.95 1.70 16.1 + 0.5 0.277

5 95.0 468 x 0.51 12.9 0.85 1.05 1.90 17.8+ 0.5 0.210

6 120.0 589 x 0.51 14.8 0.95 1.15 2.10 20.1+ 0.5 0.164

7 150.0 741 x 0.51 16.3 1.00 1.20 2.20 22.4+ 0.5 0.132

8 185 912 x 0.51 18.5 1.05 1.25 2.30 24.3+ 0.5 O.1080

9 240 1184 x 0.51 21.0 1.10 1.30 2.40 27.4 + 0.5 0.0817

10 300 1480 x 0.51 23.5 1.15 1.35 2.50 30.2 + 0.5 0.0654

Note: 1. Rope stranded conductor construction shall be adopted from sizes 10. Sq. mm and above





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3. Each particular size of conductor is required to meet a maximum resistance value as per IS 8130-2013

DATA SHEET – 2A

ELECTRON – BEAM – CROSS LINKING CURING PROCESS – SINGLE CORE

CONSTRUCTION, DIMENSION AND CONDUCTOR RESISTANCE

TEMPERATURE RANGE : - 40 TO + 120 DEG.C

MIN. BENDING RADIUS FOR OD < 10MM = 3 X D & OD > 10MM = 5 X D

Table 1

1. For control cable upto 750 volts grade with single layer insulation/ sheath for Tap

changer of Electric Locomotive AC/DC EMU. BG AC EMU & MEMU/Coaching Stock as

per CI.3.2.1 of specification

S.N. Nominal cross sectional area of core (mm2)

No of wires (typical value) x single wire dia (max) of conductor (n x mm dia)

Conductor dia. Nominal (mm)

Minimum wall thickness of insulation/ sheath (total)(mm)

Overall cable Dia (D) (mm)

Max. resistance of conductor at 20 deg. C (ohm/Km)

1 1.5 30 x 0.26 1.6 0.55 2.70+ 0.10 13.7

2 2.5 50 x 0.26 2.1 0.60 3.30+ 0.15 8.21

3 4.0 56 x 0.31 2.7 0.65 3.95+ 0.15 5.09

4 6.0 84 x 0.31 3.3 0.70 4.50 + 0.20 3.39

5 10 80 x 0.41 4.2 0.80 5.60 + 0.30 1.95

6 16 126 x 0.41 5.5 0.86 7.20 + 0.30 1.24

7 25 198 x 0.41 6.8 0.96 8.60 + 0.30 0.795

8 35 266 x 0.41 7.8 1.10 10.00 + 0.30 0.565

9 50 385 x 0.41 9.5 1.20 11.90 + 0.30 0.393

10 70 348 x 0.51 11.5 1.30 14.20 + 0.30 0.277

11 95 468 x 0.51 12.9 1.40 15.70 + 0.30 0.210

12 120 589 x 0.51 14.8 1.50 17.70 + 0.30 0.164

13 150 741 x 0.51 16.3 1.60 20.30 + 0.30 0.132

Note:1. Rope stranded conductor construction shall be adopted from sizes 10. Sq. mm and above



3. Each particular size of conductor is required to meet a maximum resistance valueas per IS8130 -2013.



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Table 2

2. For cable above 750 Volts and upto 1.8/3.0 KV (for Tap changer Electric Locomotive & AC/DC EMU, BG AC

EMU & MEMU/Coaching Stock ) as per CI.3.2.2 of specification

Note 1 : Rope stranded conductor construction shall be adopted from sizes 10. Sq.mm and above.

2. As per clause no. 3.2 of IS 8130:2013 Nominal cross section area is value that identifies a particular size of

conductor but is not subject to direct measurement.

3. Each particular size of conductor is required to meet a maximum resistance value as per IS 8130-2013.

SL. No.

Nominal cross sectional area of core (mm2)

No of wires (typical value) x single wire dia (max) of conductor (n x mm dia)

Conductor dia. Nominal (mm)

Minimum wall thickness

Overall cable Dia (D) (mm)

Max. resistance of conductor at 20 deg. C (ohm/Km)

Insulation (mm)

Sheath (mm)

Total (mm)

1 1.5 30 x 0.26 1.6 0.30 0.40 0.70 3.20 + 0.10 13.7

2 2.5 50 x 0.26 2.1 0.30 0.40 0.70 3.70 + 0.15 8.21

3 4.0 56 x 0.31 2.7 0.35 0.45 0.80 4.50 + 0.15 5.09

4 6.0 84 x 0.31 3.3 0.35 0.45 0.80 5.10+ 0.15 3.39

5 10 80 x 0.41 4.2 0.40 0.50 0.90 6.30 + 0.20 1.95

6 16 126 x 0.41 5.5 0.50 0.70 1.20 8.30 + 0.20 1.24

7 25 198 x 0.41 6.8 0.60 0.80 1.40 10.2 + 0.30 0.795

8 35 266 x 0.41 7.8 0.65 0.85 1.50 11.7+ 0.30 0.565

9 50 385 x 0.41 9.5 0.70 0.90 1.60 13.6+ 0.30 0.393

10 70 348 x 0.51 11.5 0.75 0.95 1.70 15.6+ 0.30 0.277

11 95 468 x 0.51 12.9 0.85 1.05 1.90 17.3 + 0.30 0.210

12 120 589 x 0.51 14.8 0.95 1.15 2.10 19.6 + 0.30 0.164

13 150 741 x 0.51 16.3 1.00 1.20 2.20 21.9 + 0.30 0.132

14 185 912 x 0.51 18.5 1.05 1.25 2.30 23.8 + 0.30 0.108

15 240 1184 x 0.51 21.0 1.10 1.30 2.40 26.9 + 0.30 0.0817

16 300 1480 x 0.51 23.5 1.15 1.35 2.50 29.7 + 0.30 0.0654



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DATA SHEET – 2B

ELECTRON – BEAM – CROSS LINKING CURING PROCESS – 19 CORE CABLES

CONSTRUCTION, DIMENSION AND CONDUCTOR RESISTANCE

TEMPERATURE RANGE :- 40 TO + 120 DEG.C

MIN. BENDING RADIUS = 4 X D

Table 1

For cable above 750 volts grade for Tap changer of electric locomotive, AC/DC EMU, BG AC EMU &

MEMU/coaching stock as per CI.3.2.2 of specification.

Cable shall have overall outer sheath in two layers with an open braid of cotton twin reinforced in between.

Flexing test similar to that specified in clause 9.1 of BS: 6500 – 1975 (or latest version) may be carried out as an

optional test. Procedure of test and other details for the same may be decided by the manufacturer and the user railway

mutually.

Note: 1. As per clause no. 3.2 of IS 8130:2013nominal cross section area is value that identifies a particular size of

conductor but is not subject to direct measurement.

2. Each particular size of conductor is required to meet a maximum resistance value as per 8130-2013.

S

N

Nominal

cross

sectional area of

each core

(mm2)

No of wires

(typical

value) x single wire

dia (max)

of

conductor

(n x mm

dia)

Conductor

dia.

(Nominal) (mm)

Minimum wall thickness

of core

(mm)

No

Of

cores

Thickn

ess Of

Outer Sheath

(mm

)

Overall

cable Dia

(D) (mm)

Max.

resistan

ce of conduct

or

(ohm/K

m)

Core

insulation

(mm)

Core

sheath

(mm)

Total

(mm)

1

2.5

50 x 0.26 2.1 0.30 0.40 0.70 19 1.4 23.0+0.5 8.21

2

4

7 x 8/0.31 rope Construction (1 x 8 + 6 x 8)

2.7

0.35

0.45

0.80

19

2.0

30.5 + 1.0

5.09



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APPENDIX – A

Strippablility(Clause – 7.2.7)

Test method:

A simple of 100 mm length shall be stripped 50 mm carefully. So that the remaining portion of 50

mm is not moved or deformed.

The stripped end shall be slipped into the bush according the figure. The diameter of the bore hole

shall slightly exceed the diameter of the conductor. The conductor shall be pulled out from the

insulation with constant speed by means of an elongation test equipment.

STRIPPABILITY TEST DEVICE

Retention force

Nominal cross- Section (mm2)

Full force

Minimum in N Maximum in N

1.5 2.5 4 6

20 25 30 30

60 60 100 100



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APPENDIX – B

Abrasion resistance (Clause – 7.2.14):

Abrasion resistance of sheath (Clause – 7.2.14.1):

Test method:

The equipment according the figure . A hardened tungsten carbide blade (detail x) wiil be mounted

perpendicularly to the axis of the sample and rubbed over the sample with an amplitude of

oscillation of 10 to 20mm.

40 and 60 double strokes per minute shall be made. Test weight shall be according to table given

below. Number of cycles shall be counted with a counter.

In the movement the steel blade reamer has contact to the conductor, the equipment shall be

switched of automatically by the circuit with max. DC 5 V and 0.05 A.

Sample shall be positioned straight on its support during test by a suitable fixture.

8 tests shall be performed. After each test the sample (length about 750mm) shall be moved

forward by 50mm and turned by 90 deg.C.

Requirements :

The arithmetic main value of the 8 results must be according to 7.2.14.1

Test weight:

Cross section ( mm2) Weight (Kg)

2.5 35

0.5 1

Abrasion resistance of marking (clause -7.2.14.2):

Test method:

Sample of suitable of length is fixed into apparatus according the figure .into such a manner that

the marking is positioned under the steel wire with is loaded which a test weight of 200g.

Three tests shall be made.

Amplitude of oscillation shall be 10 and 20mm. 40 to 60 double stokes per minute shall be made

.

Requirements:

According to clause 7.2.14.2



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APPENDIX – B(Cont.)

Test Arrangement for Abrasion Resistance of Sheath of Marking



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APPENDIX - C

Notch Propagation of finished cable (Clause 7.2.12)

Test method:

The test shall be carried out on a sample of suitable length. At the midpoint the covering of the

sample shall be notched with a razor blade around the whole circumference to a depth of one

third of combined minimum insulation thickness according to data sheet

The notched sample shall be wrapped around a mandrel with the diameter according to clause –

7.2.15.1 of this specification. The notch touches and is parallel to the axis of the mandrel,while

wrapping the cable sample for several turns on each side of the notch.

Then the sample is removed from the mandrel and the immersed in water during 1 hours at room

temperature, before being subjected to the voltage test, clause 7.2.1 (c) but at 50% of the specified

test voltage.

Requirements: Clause - 7.2.12



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APPENDIX-D

Pliability(Clause – 7.2.13):

This test measures the ease with the cable bends and accept a permanent set.

Test method :

Cut samples of cable to approximately 300mm long, Consecutively the same coil. The samples

shall be straightened and stored at room temperature for at least 3 hours. Test the samples using

the test rig shown in the following diagram. The diameter of the mandrel in the test rig shall be

25mm. Apply a mass of 10 kg to the cable, at the position shown in the diagram, sufficient to

bend the cable downwards through 90 + 0° – 1°. Ensure that the sample remains in this position

for 5 minutes and record the mass. After this time, remove the mass and allow the specimen to

recoil towards its original position. At a time 5, minutes after removal of the mass, record the

recoil distance – Test temperature 23 ±2 °C.

On completion of the test, the cable sample should pass high voltage test according to clause

7.2.1 (c).

Spec. No. ELRS/SPEC/ELC/0019,REV ï – î3 4 -...

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